System and Method to Reduce Standby Energy Loss in a Gas Burning Appliance and Components for Use Therewith

ABSTRACT

A system to reduce standby losses in a hot water heater is presented. The system utilizes a dual safety relay valve between the combination gas controller and the burner. The dual safety relay valve bypasses gas to a rotary damper actuator valve to position a damper flapper valve located over/inside the flue pipe. Once the flapper valve has opened to ensure combustion, the gas is allowed to flow back to the dual safety relay valve. Some of the bypass gas may be diverted to boost the pilot or to supply a booster. The dual safety relay valve is then opened to allow the gas supply to the burner. Once the burner is turned off, bypass gas bleeds out of the rotary damper actuator valve to close the damper flapper valve to reduce standby losses through the flue pipe, and to allow the dual safety relay valve to close tightly.

FIELD OF THE INVENTION

This invention generally relates to energy conservation systems, andmore particularly to energy conservation systems to be employed with gasburning appliances to reduce standby losses associated therewith.

BACKGROUND OF THE INVENTION

It has now been recognized that the world's environment is suffering toomuch from problems caused by global climate change and greenhouse gasexposure in the atmosphere. To address this problem governments are nowstarting to adopt targets for reducing the emission of greenhouse gasesto the environment and play their part to address this problem forfuture generations. While some countries have not adopted a firm goal,other countries, for example Australia, have adopted a policy forreducing greenhouse gases by 20% by the year 2020.

Greenhouse gases can be emitted from cars, industry, farming, andhouseholds to name a few. While certainly not as apparent as a largefactory with tall smokestacks, within a normal household the gas burningappliances, such as furnaces, water heaters, etc., all release suchgreenhouse gases as a by-product of the combustion process itself. Whilethe appliance industry has taken a leading role in energy efficiency andenvironmental concern, further improvement is always foremost in mind ofthe appliance design engineer.

With such further improvement in mind, especially with the increasedawareness of global climate change and changing governmentalregulations, it is noted that hot water heaters, both internal andexternally installed units, can be one of the more fairly inefficientappliances in energy conservation, and therefore require the burning ofadditional fuel to maintain the set point temperature. This, of course,results in the additional production of greenhouse gas beyond that whicha more efficient appliance would produce.

A typical hot water heater includes a vertical tank with a centrallylocated flue pipe. A gas burner is positioned underneath the tank and iscontrolled by a combination gas controller. The combination gascontroller incorporates an On/Off valve, a pilot safety circuit, pilotand main burner pressure regulators and their associated supply pipeconnections, as well as a thermostat to control the hot water heater tomaintain the water in the storage tank at a predetermined temperature.

Upon the thermostat calling for more heat, the main gas valve opens toallow gaseous fuel (gas) to flow to the main burner where it is ignitedby the pilot light. Ignition and combustion of the gas results in hotflue gas being generated. The heat from the hot flue gases istransferred to the cold water via the bottom of the tank and through thewalls of the central flue pipe. The flue gases exit out the top of thehot water heater.

There are generally two types of hot water heaters used throughout theworld classified by their installation location. For an indoor waterheater such as used in the North American market, the hot flue gasesexit through a draft diverter that is connected to a flue pipe whichpipes the flue gases safety to an outside location. Air for combustionof the gas is drawn into the combustion chamber at the bottom of the hotwater heater. For an outdoor hot water heater such as used in theAustralian market, the flue gases pass safely through a balanced flueterminal at the top of the heater to the outside atmosphere. Thebalanced flue terminal is so designed to allow a continuous supply ofair for combustion irrespective whether the burner is on or off underall types of wind conditions. The air for combustion is transferred tothe bottom of the heater internally within the appliance.

One of the current disadvantages for hot water heaters is the overallservice efficiency of the appliances. Service efficiency is defined asthe energy delivered to the hot water from the hot water heater eachday, divided by the energy burnt in the gas to heat the water and tomaintain the hot water in the tank at the desired temperature. Theservice efficiency may vary from around 0.50 or 50% for poor performingappliances, to appliances just complying to US regulations around 0.59,to superior products from 0.64 or 64% service efficiency. Low serviceefficiency may be due to poor thermal efficiency of the heat into thewater when the burner is on and/or excessive heat losses when the burneris off.

While a small percentage of the heat loss may be caused by poorinsulation from the outside of the tank, the majority of the losses aremore likely a result of excessive losses from the hot primary flue pipe(heat exchanger) in the middle of the heater. This pipe is in contactwith the hot water in the tank, and is designed to provide excellentheat transfer with the water to improve the “heat in” efficiency.

However, just as heat is transferred into the water when the burner ison, heat is also transferred out of the water when the burner is off. Asa result of this standby heat loss, relatively cold air is continuallybeing heated up and flows out of the hot water heater due to athermo-syphoning effect by the flue pipe when the burner is off. Sincethe main burner is only on for one to two hours per day heating thestored water to keep it ready for use, the surfaces inside the flue pipeare exposed to the relatively cooler air for the remaining 22 hours.This natural cooling of the heated water via the flue pipe forces thethermostat to occasionally turn on the burner to continually top up thestored hot water to the desired temperature.

Recognizing this standby heat loss problem, there have been manyattempts at providing some form of a flue damper that closes to limitthe escape of heat through the flue pipe when the burner is turned offand that reliably opens to let the flue gases escape when the burner ison. Indeed, laboratory tests have proven that dampers can reduce thestandby losses of a hot water heater by up to approx. 50%. This relatesto approx. 500 Btu/h (0.50 Mj/h), which is a huge amount of energyconsidering the product life to 10 to 15 years. While such a dampercould be electrically powered, such a damper would require additionalpower use and would need to be driven by a reliable supply. Gas powereddampers, that is dampers driven by the gas used for combustion,alleviate the problems of additional electrical power use and reliablesupply. Unfortunately, the appliance industry generally and hot waterheater manufacturers specifically have been frustrated by the fact thatgas operated dampers “nearly work”. They are not popular and commonlyhave many problems and service issues.

One significant problem experienced by gas operated flue dampers relatesto candling of the diminishing flame on shut down of conventionalburners and low NOx burners. This candling effect results from thedraining of the gas in the burner feed pipe that leads from the damperactuator valve to the burner after the burner has been commanded off.Since the gas operated damper valve is located on the flue pipe at thetop of the hot water heater and the burner is located at the bottom, thegas pipe from the valve to the burner runs at least the length of thestorage tank. As a result of the existence of gas in the pipe after thevalve have been shut, a small flame at the injector continues to burnuntil the pipe is drained, which results in the gradual build up of sootin the burner. This, in turn, often results in poor combustion, furtherincreasing the production of greenhouse and other dangerous gasses.Candling is especially a problem with installations where the gaseousfuel used is heavier than air such as propane, butane gas, etc.

To address the systemic problem of candling with prior gas operateddampers, some designs incorporate an additional damper valve bleed line,a flow orifice member, and a separate vent pilot. Unfortunately, suchadditional plumbing and components increase the complexity and cost ofsuch systems, as well as reducing the overall reliability of the systemdue to the increase in components. In the highly cost competitiveappliance industry, even with the overall lifetime cost of operationreduction and with the reduction in production of greenhouse gasses,such additional expense makes such hot water heaters undesirable byconsumers.

Another problem with some gas controlled damper valves is that they cantrap gas within the valving damper system. This often results inallowing the damper only partially to close the damper, reducing theenergy savings by allowing some flow therethrough.

To address such problems existing in the art, the inventors of theinstant application invented a new and improved standby heat losscontrol system as described in co-pending application Ser. No.12/175,551, entitled System and Method to Reduce Standby Energy Loss ina Gas Burning Appliance, filed on Jul. 18, 2008, and assigned to theassignee of the instant application, the teachings and disclosure ofwhich are hereby incorporated in their entireties by reference thereto.More specifically, such system provides a gas operated damper system fora hot water heater to enable hot water heaters to operate moreefficiently thus reducing greenhouse gases. The system advantageouslyreduces the standby heat losses that occur as a result ofthermo-syphoning of the heat from the hot water in the storage tank of ahot water heater by the flue pipe when the burner is off.

While this prior system provides significant advantages and advancementsin energy savings, continued improvements in operating efficiency,safety, and cost reduction are desired. Embodiments of the presentinvention provide such improvements in an energy savings damper system.These and other advantages of the invention, as well as additionalinventive features, will be apparent from the description of theinvention provided herein.

BRIEF SUMMARY OF THE INVENTION

In view of the above, embodiments of the present invention provide a newand improved standby heat loss control system that overcomes one or moreof the problems exiting in the art and provides improvements over theinventors' prior system. More specifically, embodiments of the presentinvention provide a new and improved gas operated damper system for ahot water heater to enable hot water heaters to operate more efficientlythus reducing greenhouse gases. Preferably, embodiments of the presentinvention provide a new and improved gas operated damper that reducesthe standby heat losses that occur as a result of thermo-syphoning ofthe heat from the hot water in the storage tank of a hot water heater bythe flue pipe when the burner is off.

In particular, embodiments of the present invention provide a rotarydamper actuator valve and dual safety relay valve downstream of thecombination gas controller. Both valves are operated in series by theuse of bleed gas supplied by the combination gas controller. The bleedgas pressure operates the appliance damper actuator system in acontrolled and defined safe manner, then supplies gas to operate thedual safety relay valve.

In one embodiment, the dual safety relay valve is configured to bypass asmall amount of gaseous fuel to the rotary damper actuator valve whenthe thermostat in the combination gas controller calls for heat. Thebleed gas flows to the rotary damper actuator valve and causes operationof the damper via a damper flapper valve to open the flue pipe. When thedamper is open, and only then, the rotary damper actuator valve, via adamper actuator safety valve, allows the bleed gas to be piped back downto the dual safety relay valve to actuate it, opening it and allowinggas to flow to the main burner of the hot water heater.

In one of the preferred embodiments, the system automatically opens andcloses the rotary damper actuator valve, its associated mechanism andthe dual safety relay valve in a defined and controlled manner. Thevalving is designed so that no gas can physically pass to the mainburner if the rotary damper actuator valve and connected mechanisms havenot moved open sufficiently for good combustion. In addition, the rotarydamper actuator valve and connected mechanism automatically and safelyclose off the appliance's flue pipe (heat exchanger) from freeventilation immediately after the burner off cycle is completed.

The configuration of valves prevents gas from passing to the main burneruntil the piped bleed gas pressurizes a rotary damper actuator valvediaphragm, which in turn moves the diaphragm, piston, and rotates thecorresponding linkage attached to the damper flapper valve at the outletof the water heater flue pipe to open the damper flapper valve.

In one embodiment, the damper diaphragm and piston has an undersidelinkage to a damper actuator safety valve on the gas side. Continueddiaphragm and piston movement after opening the damper finally drags adamper actuator safety valve from its seat, thereby allowing bleed gasto pass. This bleed gas then pressurizes the dual safety relay valve.Diaphragms in the dual safety relay valve are forced to move by thispressurizing bleed gas, which opens each of the series connected mainrelay valves to allow gas to flow to the main burner. The bleed gas, asit is continually being passed from the combination gas controller,through the rotary damper actuator valve, and back to the dual safetyrelay valve, is finally mixed into the main gas to the burner.

In one embodiment the dual safety relay valve includes two back to backvalves manufactured 180 degrees to each other but on the same axis toprovide an efficient compact design. The miniaturization provided bythis orientation offers installation and cost advantages, allowingfitment under the existing gas controllers, e.g. under the existingthermostat on the burner feed pipe. This is an advantage for new heatersand also retrofit applications on existing installed heaters. Further,the dual construction ensures compliance with redundant safety standardsand is cheaper to manufacture than two discrete relay valves. In anembodiment, the dual safety relay valve is designed to operate withsmall gas bleed systems for compatibility with ignition pilots, such asthe system described in co-pending application Ser. No. 12/175,504,entitled Micro-Pilot for Gas Appliance, filed Jul. 18, 2008, andassigned to the assignee of the instant invention, the teachings anddisclosure of which are hereby incorporated in their entireties byreference thereto.

In one embodiment the rotary damper actuator valve includes a damperactuator safety valve and linkage. The damper actuator safety valve inthe rotary damper actuator valve is designed to open at a predeterminedcorrect angular position of pressurization of the diaphragm. Thepressurization movement rotates the shaft and opens the connectedflapper valve sufficiently to ensure good combustion before allowingbleed gas to pass back to the dual safety relay. The design of the valvearm and linkage arm provides a good mechanical advantage to close thedamper actuator safety valve tightly on its seat to stop any bypass ofbleed gas when the damper flapper valve is in a closed position. Themechanical advantage generated by the linkage also allows more positiveopening and closing of the damper flapper valve and improves safetyunder low gas pressures. The efficient design allows a smaller valve pergiven torque force generated than a conventional linear damper valve.Indeed, the rotating folding diaphragm provides more torque on therotating shaft than other actuators. This shaft is attached to thedamper flapper valve shaft. With more torque generated, the damperflapper valve shaft will overcome more opening friction in lifting thedamper flapper valve off its seat compared with conventional linearvalves. As such, the rotary actuator will therefore operate at lower gaspressures. It also gives the advantage that the damper flapper valve canbe miniaturized. Due to these characteristic the design is smaller, morecompact, requires less metal and therefore is cheaper.

In one embodiment of the damper flapper valve that is particularly wellsuited for use with outdoor square gas heaters, the design slipsmanufacturing tolerances by using the edge of the flapper valve seat asa floating fulcrum point. It allows for inexpensive sheet metal to beused rather that expensive die cast machined parts, and can be made forsquare of round ducting. In one embodiment there is incorporated anindependent false flapper valve seat to close off tightly with theflapper. The design slips the manufacturing tolerances between tank fluepipe and the heater jacket.

In one embodiment of the damper flapper valve that is particularly wellsuited for use with indoor gas heaters, the damper flapper valveoperating principle relies on an off-center axis weight distribution toautomatically close the damper flapper valve should no external force bepresent. A hook shaped section at the end of the damper flapper actuatorshaft, when it rotates due to pressurization, is used to force open thedamper flapper valve by a weighting downward pressure on one side of theflapper valve. It creates this force as the hook hits the flapper valveduring its rotation. The actual damper flapper valve is not preloadedwhen the burner is off as the shaft is not designed to contact thedamper flapper valve.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 is an isometric view of an indoor hot water heater havinginstalled thereon an embodiment of the bypass gas operated standby heatloss prevention system of the present invention;

FIG. 2 is an enlarged partial section view of the hot water heater ofFIG. 1 illustrating in greater detail the damper and rotary damperactuator valve;

FIG. 3 is an isometric view of an square outdoor water heater havinginstalled thereon on embodiment of the standby heat loss preventionsystem of the present invention showing the position of the rotarydamper actuator valve and dual safety relay valve;

FIG. 4 is a block diagrammatic view of the primary functional activitycomponents of the gas control system of a typical storage hot waterheater;

FIG. 5 is a block diagrammatic view of functional activity components ofone embodiment of the gas control system of a storage hot water heatershowing the additional components of the standby heat loss controlsystem;

FIG. 6 is a diagrammatic cross section of a dual safety relay valveconstructed in accordance with one embodiment of the present inventionin a closed position;

FIG. 7 is a diagrammatic cross section of the dual safety relay valve ofFIG. 6 in an open position;

FIG. 8 is a block diagrammatic view of functional activity components ofan embodiment of the gas control system of the present inventionutilizing a pilot boost connection;

FIG. 9 is a block diagrammatic view of components of an embodiment ofthe gas control system of the present invention utilizing a boosterpilot;

FIG. 10 is a cross-sectional side view illustration of an embodiment ofa rotary damper actuator valve constructed in accordance with theteachings of the present invention in a closed position;

FIG. 11 is a cross-sectional side view illustration of the rotary damperactuator valve of FIG. 10 in an open position;

FIG. 12 is a cross-sectional side view illustration of an alternateembodiment of a rotary damper actuator valve constructed in accordancewith the teachings of the present invention in an open position;

FIG. 13 is a simplified isometric view of an embodiment of a damperflapper valve constructed in accordance with the teachings of thepresent invention engaging a gas appliance flue pipe in a closedposition;

FIG. 14 is a simplified isometric view of the damper flapper valve ofFIG. 13 engaging a gas appliance flue pipe in an open position;

FIG. 15 is a simplified isometric view of an alternate embodiment of adamper flapper valve utilizing a valve seat bracket configured forfitment into a balanced flue terminal of an outdoor water heaterconstructed in accordance with the teachings of the present invention inan open position;

FIG. 16 is a simplified isometric view of the damper flapper valveutilizing a valve seat bracket configured for fitment into a balancedflue terminal of an outdoor water heater of FIG. 15 in a closedposition;

FIG. 17 is an enlarged partial view of the damper flapper valveutilizing a valve seat bracket configured for fitment into a balancedflue terminal of an outdoor water heater of FIG. 16 illustratingengagement with the crank shaft;

FIG. 18 is a side view illustration of FIG. 17 illustrating engagementbetween the damper flapper valve and the valve seat bracket;

FIG. 19 is a simplified isometric view of the damper flapper valve ofFIG. 15 illustrating fitment of the valve seat bracket into the balancedflue terminal of an outdoor water heater in a closed position;

FIG. 20 is a simplified isometric view of the damper flapper valve ofFIG. 15 illustrating fitment of the valve seat bracket into the balancedflue terminal of an outdoor water heater in an open position;

FIG. 21 is a simplified isometric view of an alternate embodiment of adamper flapper valve configured for fitment into the flue pipe of a gasburning appliance constructed in accordance with the teachings of thepresent invention;

FIG. 22 is an alternate view of a simplified isometric illustration ofthe damper flapper valve of FIG. 21;

FIG. 23 is a partial cross-sectional isometric view of the damperflapper valve of FIG. 21 illustrating features of the valve seat collarpositioned within the flue pipe of the gas burning appliance;

FIG. 24 is a side view illustration of the cross-sectional isometricview of the damper flapper valve of FIG. 23 illustrating opening of thedamper flapper valve;

FIG. 25 is an isometric illustration of the flapper disc used in thedamper flapper valve of FIG. 21;

FIG. 26 is an isometric illustration of an alternative embodiment of adamper flapper valve utilizing a housing configured for fitment onto theflue pipe of a gas burning appliance constructed in accordance with theteachings of the present invention;

FIG. 27 is an exploded isometric illustration of the damper flappervalve and housing of FIG. 26; and

FIGS. 28-32 are schematic gas flow diagrams illustrating sequential gasflow and damper control provided by one embodiment of the standby heatloss control system of the present invention.

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, there is illustrated in FIG. 1 an indoorhot water heater 100 such as typically installed in dwellings in theNorth American market having installed thereon an embodiment of thestandby heat loss control system 102 of the present invention. It shouldbe noted that while the following description will discuss variousembodiments of the present invention, such embodiments and operativeenvironments to which these embodiments find particular applicabilityare provided by way of example and not by way of limitation. Forexample, the embodiment illustrated in FIG. 1 having the components ofthe standby heat loss control system 102 exposed, such as in a retrofitinstallation on an existing hot water heater 100, may instead in adifferent embodiment have one or more of such components and plumbingintegrated into the combination gas controller 130 and/or housing 104such that they are not visible to the consumer. Embodiments of thepresent invention may also find applicability in other gas burningappliances, e.g. a furnace, gas log, etc., which typically utilize aflue pipe to exhaust combustion gases during burner operation.

Returning specifically to FIG. 1, the hot water heater 100 includes acylindrical storage tank 106 for storing the water to be heated by theburner (not shown) located in the bottom 108 of the hot water heater100. The housing 104 around the storage tank 106 is typically in theform of an insulated round jacket to prevent heat loss though theexterior surface. The heat from the burner is exchanged with the waterin the storage tank via the flue pipe 110 that leads from the burnerthrough the storage tank 106 to a draft diverter 112 located on the topof the hot water heater 100. The draft diverter 112 is positioned tocollect the hot flue gases from the flue pipe 110, and is coupled to apipe that is positioned to carry these flue gasses out of the dwellingin which the hot water heater 100 is installed.

In this embodiment, standby heat loss is substantially reduced by theinclusion of a rotary damper actuator valve 114 that is located at thetop of the hot water heater 100. The rotary damper actuator valve 114 isconnected to a damper flapper valve 118 located on the flue pipe 110.This damper flapper valve 118 is used, as will be described more fullybelow, to close off the flue pipe 110 when the burner is off. The shapeof the damper flapper valve 118 is normally round to close off thetypical round flue pipe 110, although it would be square to close offsquare ducting, etc.

As may be seen from the enlarged partial view of FIG. 2, the inlet 124of the rotary damper actuator valve 114 is connected via small borepiping 120 to the inlet of the dual safety relay valve 122 (shown inFIG. 1). The outlet 126 of the rotary damper actuator valve 114 is alsoconnected via small bore piping 128 back to the dual safety relay valve122, the details of which will be discussed more fully below with regardto FIGS. 6 and 7.

Returning to the illustration of FIG. 1, it may be seen that the dualsafety relay valve 122 is positioned between the hot water heater'scombination gas controller 130 and the burner (not shown). Specifically,the outlet gas feed pipe 132 from the combination gas controller 130 isnow connected to the dual safety relay valve 122, which in turnconnected is to the burner feed pipe 134 which leads to the burner.

Although not recognized by prior gas operated damper designs, the dualsafety relay valve 122 should be located immediately after the waterheater combination gas controller 130 but as close as possible to theburner so to reduce the effect of pre-ignition and candling.Pre-ignition is defined as attempting to ignite the issued air/gasmixture from the burner ports too early (pressure within the burner headunstable) causing the explosive mixture to flash back through the burnerports and ignite within the burner head. Candling is defined as thedraining of the gas in the burner feed pipe after the burner has beencommanded off, so as to cause a small flame at the injector resulting inthe gradual sooting up of the burner and bad combustion. This isespecially a problem with gases heavier than air such as propane, butanegas.

As discussed above, markets outside of North America, such as inAustralia, install their hot water heaters outside of the dwellings. Anembodiment of one such outdoor hot water heater 136 is illustrated inFIG. 3. The outdoor hot water heater 136 includes the cylindricalstorage tank 106 housed in a rectangular jacket 138. A balanced flueterminal 140 is located on the top to collect the hot flue gases anddisperse them from the front of the hot water heater 136.

The rotary damper actuator valve 114 is located inside the balanced flueterminal 140, attached to the outside of the transfer duct, which isadjacent to the heater flue pipe as it exits into the transfer duct(show in this illustration as 110 for ease of understanding). In thisembodiment the rotary damper actuator valve 114 is located close to thecylinder flue pipe 110 outlet in order to reduce standing losses asdiscussed above. It may also be located either outside the terminal 140away from the fresh air inlet or alternately be positioned in theterminal 140 but located so as not to create any turbulence under windycondition, e.g. in a static wind pocket within the terminal 140. In analternate embodiment, to be discussed below with regard to FIGS. 15-20,the damper flapper valve 118 utilizes a valve seat bracket 210configured for fitment into the balanced flue terminal 140 of theoutdoor water heater 136 to ensure proper close off and ventingtherethrough.

Returning to the embodiment illustrated in FIG. 3, the damper flappervalve 118 to close off the flue pipe 110 is located immediately over theoutlet of the flue pipe 110 inside the transfer duct and driven by therotary damper actuator valve 114. Small bore piping 120, 128 is used toconnect the dual safety relay valve 122 to the rotary damper actuatorvalve 114 as in the previous embodiment. The outlet gas feed pipe 132from the combination gas controller 130 is now connected to the dualsafety relay valve 122, which in turn is connected to the burner feedpipe 134 on supply gas to the burner. The tank 106 is insulated withinthe square jacket 138, which also provides internal pathways for the airto be transferred from the top terminal 140 to the burner at the bottomof the appliance.

To help understand the control provided by the various components ofembodiments of the present invention, an understanding of a typicalwater heater combination gas controller 130 must first be had. To aidthis, attention is now directed to the block diagram of FIG. 4, whichillustrates the functional blocks of a standard hot water heatercombination gas controller 130. The combination gas controller 130incorporates in block 142 an off/pilot/on valve, pilot electro magneticsafety valve thermocouple system and a pilot regulator. The combinationgas controller 130 also includes a thermostat 144 to control the gas tothe burner 148 to heat up the water to a predetermined temperature, anda gas regulator 146 to regulate pressure to the main burner 148. Toestablish a safe pilot flame for burner ignition, functional block 142supplies gas via a pilot feed pipe 150 to the pilot 152. A flame sensor154, such as a thermocouple, is used to sense the presence of flame atthe pilot 152 as a feedback to block 142.

With this basic understanding in mind, attention is now directed to FIG.5, which illustrates a simplified block diagram showing the functionalconnections between the combination gas controller 130 and components ofone embodiment of the standby heat loss prevention system 102 of thepresent invention. It should be noted, however, that while thisdescription and illustration show the dual safety relay valve 122located outside of the housing of the combination gas controller 130,other embodiments of the present invention include the dual safety relayvalve 122 within the same housing as the combination gas controller 130(which refers to the functional elements and not the packaging thereof).As such, in the following description and claims, when the dual safetyrelay valve 122 is described as being installed between the combinationgas controller 130 and the burner 148, this is a functional descriptionand not a physical one, i.e. the dual safety relay valve 122 may bepackaged within the same housing of the combination gas controller 130or outside of the housing of the combination gas controller 130.

In either physical layout, the combination gas controller 130 remainsunchanged in operation as discussed above. However, instead of havingthe gas regulator 146 coupled to the burner feed pipe 134, it is coupledto the dual safety relay valve 122, which is then coupled to the burnerfeed pipe 134. As discussed above, small bore pipe 120, 128 is used tocouple the dual safety relay valve 122 to the rotary damper actuatorvalve 114 to drive the damper flapper valve 118. The advantage of usingbleed gas to control the position of the damper flapper valve 118 andthe operation of the dual safety relay valve 122, as opposed to usingthe main gas flow in prior designs, will be discussed more fully belowonce the details of an embodiment of the various components are betterunderstood.

The details of one embodiment of a dual safety relay valve 122 are shownin the cross sectional illustrations of FIGS. 6 and 7. As may be seen,the dual safety relay valve 122 contains an inlet 156 to receive gasfrom the combination gas controller 130. A first main controlling valve158 with a first valve return spring 160 and a secondary maincontrolling valve 212 with a second valve return spring 214 arepositioned in series between the inlet 156 and the outlet 162.Preferably, the first and the second main controlling valves 158, 212are included in a single housing but oriented 180° to each other on thesame axis between the inlet 156 and the outlet 162. The inlet chamber ofthe dual safety relay valve 122 includes a first connection port 164 forsupplying bleed gas via small bore piping 120 to the rotary damperactuator valve 114.

In one embodiment wherein the first and second main controlling valves158, 212 operate together, a second connection port (not shown) forreceiving bleed gas back from the rotary damper actuator valve 114 viathe small bore piping 128 is located in the diaphragm control chambersbetween a first main diaphragm 166 and the cover 168 and between asecond main diaphragm 216 and the cover 218. The communication of thebleed gas to both the first and the second main diaphragms 166, 216 topressurize them and actuate the first and second main controlling valves158, 212 may be through a flow passage within the housing of the dualsafety relay valve 122, or may be provided by external piping. In eitherconfiguration, the actuation of both the first and the second maincontrolling valves 158, 212 will occur more or less at the same time asthe pressure in each of the diaphragm control chambers will buildapproximately equally and assuming that the spring force from each ofthe first and second valve return springs 160, 214 are approximatelyequal.

In another embodiment wherein the first and second main controllingvalves 158, 212 operate in sequence, the second connection port forreceiving bleed gas back from the rotary damper actuator valve 114 viathe small bore piping 128 is located in the diaphragm control chamberbetween a first main diaphragm 166 and the cover 168. A flow passage(not shown) then connects the second diaphragm control chamber betweenthe second main diaphragm 216 and the cover 218 to a gas flow chamberlocated downstream of the valve seat 220 of the first main controllingvalve 158. Once the bleed gas from the rotary damper actuator valve 114has caused the first main diaphragm 166 to open the first maincontrolling valve, gas will flow into the gas flow chamber between thefirst and second main controlling valves 158, 212. A portion of this gaswill then travel through the flow passage to the second diaphragmcontrol chamber between the second main diaphragm 216 and the cover 218,causing the second main diaphragm 216 to expand and open the second maincontrolling valve 212. This will then allow the gas to flow to theoutlet 162 as shown in FIG. 7.

As will now be apparent, for each of the first and second maincontrolling valves 158, 212, a diaphragm (166, 216) is positioned withinthe diaphragm control chamber and is operatively coupled to the mainvalve control shaft 172, 222. Displacement of the diaphragm 166, 216based on pressure within the diaphragm control chamber will operate toopen or allow the first and second main controlling valves 158, 212 toclose under pressure of spring 160 as discussed above. The purpose ofthe dual safety relay valve 122 with its two anti-parallel positionedand serially connected main controlling valves 158, 212 is to enhancethe safety of the appliance through having redundant valve control ofthe supply of gas to the main burner. The improved safety relies on thefact that it is unlikely that a possible faulty operation due a springfailure, diaphragm rip, dirt under the valve seat, etc. is likely tohappen to both valves at the same time. Since they are in series then atleast one valve will operate properly until the other one is serviced.The anti-parallel orientation provides an efficient compact design, andallows fitment under existing combination gas controller 130, such ase.g. a Robertshaw R110, R220 or SIT AC3 controller, for retrofitapplications.

In an alternate embodiment, the dual safety relay valve 122 includes anoptional booster pilot gas connection leading from the diaphragm controlchamber for providing gas to a booster pilot, such as that described inco-pending application Ser. No. 12/175,504, entitled Micro-Pilot for GasAppliance, filed Jul. 18, 2008, and assigned to the assignee of theinstant invention, the teachings and disclosure of which are herebyincorporated in their entireties by reference thereto. As illustrated inFIG. 8, such a booster pilot gas connection 174 may be used to supplyadditional gas to the pilot feed pipe 150 to increase the pilot 152flame just prior to opening of the main flow of gas to the burner 148 toaid in ignition thereof. In another embodiment as illustrated in FIG. 9,the booster pilot gas connection 174 could be coupled to a booster pilot178 in addition to the pilot 152. In such an embodiment, the pilot 152can be a micro pilot having a very small flame that is at least capableof igniting the gas flowing from the booster pilot gas connection 174 tothe booster pilot 178, which is then used to ignite the main flow of gasto the burner 148.

Turning now to FIG. 10, there is illustrated a simplifiedcross-sectional view of an embodiment of a rotary damper actuator valve114 shown in a closed position. The rotary damper actuator valve 114incorporates a gas inlet 124 formed in one half of the casing 184, asecond half of the casing 186, a diaphragm 188, a rotatable shaft 192 indriven communication with a piston 224 coupled to the diaphragm 188, asafety valve connection hook 198, a damper actuator safety valve 200, asafety valve return spring 226, a bypass 202 in the damper actuatorsafety valve 200, and a outlet gas connection 126 to bleed gas back tothe dual safety relay valve 122. The damper actuator safety valve bypass202 is a small pilot hole, by way of example only approx. 0.50 mmdiameter, to ensure all the gas drains from the rotary damper actuatorvalve 114 when the gas burner is turned off to allow the damper flappervalve 118 to tightly close thereafter, particularly when natural gas isused.

In an alternate embodiment, particularly well suited for use with LPgases, neither the safety valve return spring 226 nor the bypass 202 inthe damper actuator safety valve 200 are used. Instead, a torsion spring(not shown) surrounding the rotating shaft 192 is used to return thedamper actuator safety valve 200 to its closed position and a detentmechanism (not shown) similar to the detent mechanism 228 shown in FIG.12. In such an embodiment, the safety valve connection hook 198 is sodesigned so that it does not engage the valve arm 204 untilapproximately 90% of travel so as to allow good combustion beforedragging the damper actuator safety valve 200 off its seat. In doing soit also drags the valve arm 204 containing a small spigot (not shown)past the detent in the detent mechanism 228 (see FIG. 12) to the detentopen position. Upon close down the spigot and detent mechanism is alsoso designed to keep the safety valve open until the top of the diaphragmkeeper hits the top of the valve arm 204 and moves it to the detentclosed position (on the other side of the detent from that shown in FIG.12) and closes the safety valve after approximately 90% of gas isdrained.

As indicated above, upon the thermostat calling for heat, gas issupplied to inlet of the closed dual safety relay valve 122. Gas is thensupplied to the rotary damper actuator valve inlet 124 pressuring thediaphragm 188. The displacement of the diaphragm 188 rotates the piston224, which rotates shaft 192. The shaft 192 either couples to or forms aportion of the crankshaft rod 190. As such, rotation of shaft 192rotates crankshaft rod 190 to open the damper flapper valve 118sufficiently for good combustion.

The continued pressurising and resulting further displacement of thediaphragm 188 and piston 224 finally causes the safety valve connectionhook 198 to catch the valve arm 204 to drag the damper actuator safetyvalve 200 off its seat. This allows gas to be bled back to the dualsafety relay valve 122 through outlet 126 as shown in FIG. 11.

This function of the gas safety valve 200 being finally dragged off itsseat when the damper flapper valve 118 is opened sufficiently for goodcombustion may be defined by a damper actuator safety valve dragdistance. This distance must be accurately controlled for safety and maybe accomplished in many ways, e.g. the relative lengths of the safetyvalve connection hook 198 and the valve arm 204. That is, the valve arm204 and safety valve connection hook 198 are sized relative to oneanother to ensure proper damper actuator safety valve drag distance.

Other embodiments may use a chain between the diaphragm 188 and piston224 and the damper actuator safety valve 200 of a length to ensure thatthe chain is only taut, and therefore finally drags the damper actuatorsafety valve 200 off its seat once the damper actuator safety valve dragdistance has been spanned. Other mechanisms may include a rod with stop,located inside a tube with a slot, or that shown in FIGS. 2 and 3 ofU.S. Pat. No. 4,076,171.

Another mechanism is illustrated in the alternate embodiment of therotary damper actuator valve 114′ illustrated in FIG. 12. In thisembodiment, the safety valve connection hook 198 has a projection (notshown) that slides along a slot (not shown) in the valve arm 204 as thepiston 224 rotates under the force of the expanding bellows 188. Thelength of the slot and the safety valve connection hook 198 then controlthe damper actuator safety valve drag distance. As discussed above, insuch an embodiment the safety valve connection hook 198 is so designedso that it does not engage the valve arm 204 until approximately 90% oftravel so as to allow good combustion before dragging the damperactuator safety valve 200 off its seat. In doing so it also drags thevalve arm 204 containing a small spigot 270 past the detent 272 in thedetent mechanism 228 to the detent open position shown. Upon close downthe spigot 270 and detent 272 operate to keep the safety valve 200 openuntil the top of the diaphragm keeper hits the top of the valve arm 204and moves it to the detent closed position with the spigot 270 on theother side of the detent 272 from that shown in FIG. 12 and closes thesafety valve 202 after approximately 90% of gas is drained.

Regardless of the mechanism to control the damper actuator safety valvedrag distance, once the thermostat no longer calls for heat and thesupply of gas is stopped, the safety valve return spring 226 (or thetorsion spring through the shaft 192 and operation of the detentmechanism 228) acts on the damper actuator safety valve 200 to close itand stop the pressurizing flow of gas from outlet 126 before the damperflapper valve 118 has closed. This will result, as will be discussedmore fully below, in the closing of the dual safety relay valve 122 toturn off the burner of the appliance before the damper flapper valve 118closes the flue.

The closing of the flue pipe 110 by the damper flapper valve 118 maytake numerous forms in various embodiments of the present invention. Inone embodiment illustrated in FIG. 13 in a closed position and in FIG.14 in an open position, the damper flapper valve 118 and rotary damperactuator valve 114 are positioned proximate the flue pipe 110 forclosing engagement with a top edge thereof. In a closed position asshown in FIG. 13, the damper flapper valve 118 is positioned over thetop of the flue pipe 110 so as to close off any opening therebetween andreduce thermal siphoning. As may be seen from the open positionillustrated in FIG. 14, to aid in the closure of the flue pipe 110, avalve seat 230 may be positioned on the top opening of the flue pipe 110to ensure positive closure and increasing the effectiveness of thedamper flapper valve 118.

While such an embodiment is effective, it is dependent on good tolerancematching between the horizontal position of the damper flapper valve 118and the upper edge of the flue pipe 110. While such can be easilycontrolled when manufacturing the appliance, or may be compensated byinclusion of the valve seat 230, typically the tolerance stack up insuch appliance manufacturing processes do not lend themselves to a tightfit.

As such, and in order to slip or overcome such tolerance issues,alternate embodiments, such as that shown in FIGS. 15-20 for use onappliances that have a square flue gas transfer duct transporting thehot flue gases to the front of the appliance, such as currently used inoutdoor gas water heaters in Australia, are provided. In such aninstallation, a valve seat bracket 210 may be utilized (FIG. 15illustrates an open position and FIG. 16 a closed position). The valveseat bracket 210 is configured to fit into the square transfer duct ofthe terminal 140 (see FIGS. 19 and 20) of the outdoor water heater.

The height of the valve seat bracket 210 takes into account the maximumdesign tolerance of component parts relative to the amount of height theflue pipe 110 will penetrate through the jacket top of the outdoor waterheater to ensure that the top surface forming the false flapper valveseat is above the top of the flue pipe 110. The surrounding space at thetop of the flue pipe may be insulated to further reduce heat losses.This height allows this embodiment to overcome the issue of tolerancestack up which may be as large as six to eight millimeters.

The damper flapper valve 118 utilizes the edge 232 (see FIG. 18) of thevalve seat bracket 210 as a floating fulcrum point. In this way, thedamper flapper valve 118 is simply allowed to lay on top of the valveseat bracket 210 in a closed position (see FIGS. 16 and 19). Because thevalve seat bracket 210 is sized to fit inside the terminal 140, i.e.having edges that contact the side walls or otherwise minimize gapstherebetween, there is little to no heat loss through the transfer duct234 of the terminal 140 while the damper flapper valve 118 is lying ontop of the valve seat bracket 210. In other words, contact between thevalve seat bracket 210 and the walls of terminal 140 ensures that thethermal siphoning is precluded therebetween. Only when the damperflapper valve 118 is in an open position, such as shown in FIG. 20, canthe hot flue gases flow from the top of the flue pipe 110 through theopening in the valve seat bracket 210 and out through the transfer duct234.

The use of the valve seat bracket 210 fitted into the terminal 140eliminates the necessity of ensuring that the damper flapper valve 118can seal on the top of flue pipe 110 (such as is required in theembodiment illustrated in FIGS. 13 and 14). This eliminates the need toprecisely control the positioning of the top of the flue pipe 110 sothat it mates with the damper flapper valve 118 once it and the rotarydamper actuator valve 114 are fitted onto the appliance.

As may be seen best from the enlarged partial view of FIG. 17, fold uptabs (236) 238 are formed on either side of the v-shaped bend in thecrank shaft 190. A capture tab 240 is also formed to engage the crankshaft 190 in the center of the v-shape bend therein. In this way, therotating crank shaft 190 has some freedom of rotation before affectingthe position of the flapper valve relative to the valve seat due to thelose capture of the tabs. In such a configuration, the angle of openingof the damper flapper valve 118 is roughly limited by the angle of thepositioning legs 242 of the valve seat bracket 210. The outdoor heaterdamper flapper valve will normally open approximately sixty degrees dueto the internal square ducting of the appliance whereas the indoorheater's damper flapper valve normally opens a full ninety degrees. Theopening of the actuator safety valve is adjusted accordingly with eachheater to ensure good combustion. In the embodiment of the valve seatbracket 210 illustrated in FIGS. 15-20, a pair of downwardly dependingwalls 244 are included to aid the positioning and stability of the valveseat bracket 210 within the terminal 140. However, those skilled in theart will recognize that such are not required within the scope of theinvention.

In an alternate embodiment of the present invention illustrated in FIG.21, the damper flapper valve 118 is contained in a damper flapper valvehousing 246 that is configured to fit over the water heater's primaryflue pipe 110 to also slip the tolerance issue discussed above,particularly in retrofit applications. As will be recognized by thoseskilled in the art from the previous discussions, the damper flappervalve housing 246 may be the flue pipe 110 itself such as illustrated inFIG. 1, particularly for OEM installations of the damper flapper valve118. Returning to the embodiment illustrated in FIG. 21, the damperflapper valve housing 246 includes a mounting adapter housing 248 formounting the rotary damper actuator valve 114 thereon, and asillustrated in FIG. 22, for receiving the shaft 192 therethrough. Theheight of the damper flapper valve housing 246 may be such to allow itto engage the draft diverter 112 (see FIG. 1), or may be limited toprovide a gap therebetween.

Within the damper flapper valve housing 246 is contained a valve seatring 250. This valve seat ring 250 has an upper valve seat surface 252and a lower valve seat surface 254 as may be best seen from the partialcutaway illustrations of FIGS. 23 and 24. As illustrated in FIG. 25, thedamper flapper valve 118 includes a pair of radius transition tabs 256separating a larger and smaller radius portion of the damper flappervalve 118. This allows one portion of the damper flapper valve 118 tocontact the upper valve seat surface 252 while the other portioncontacts the lower valve seat surface 254 as illustrated in FIG. 23 in aclosed position and in FIG. 24 in an open position.

In a preferred embodiment, the position of the radius transition tabs256 are positioned to allow the damper flapper valve 118 to be overcenter weighted. This allows the damper flapper valve 118 to close dueto gravity when assembled on the valve seat ring 250 when no other forceis available. Advantageously, this design of the damper flapper valve118 also allows for natural explosion relief due to the greater surfacearea relative to the central axis at its fulcrum point. In other words,the damper flapper valve 118 is freely able to open due to upward airpressure caused by rough or explosive ignition of fuel in the burner.This over center design allows the air pressure in the flue pipe tocreate a greater force on one side of the damper flapper valve 118 tomomentarily open it, due to a larger surface area on that side of thedamper flapper valve 118, relative to its fulcrum. Once the pressuretransient has subsided, the over center weighted design of the damperflapper valve 118 will allow the damper flapper valve 118 to again closeor return to its commanded position relative to the valve seat ring 250.This may be aided by deliberately weighting one side of the damperflapper valve 118.

In an alternate embodiment of the present invention as illustrated inFIGS. 26 and 27, the damper flapper valve housing 246′ is constructedfrom a two piece construction designed to integrate to existing designedwater heaters 100. Such a configuration may be fitted in the factory orretrofitted to an existing product installed in a home or business. Thebase 258 of the damper flapper valve housing 246′ is preferablyconstructed from sheet metal, and includes a press metal extrusionforming the valve seat ring 250′. This valve seat ring 250′ is sized tofit over the primary flue pipe protruding through the jacket of thewater heater 100. One of the sides of the base 258 includes mountingholes 264 for mounting the rotary damper actuator valve 114, as well asa hole 266 to accommodate shaft 192 that couples to the rotating damperactuator valve 114.

The top 260 of the damper flapper valve housing 246′ is also preferablyconstructed from sheet metal, and includes an extrusion downward to fitover the base valve seat ring 250′ extrusion to form a continuouspassageway through the damper flapper valve housing 246′. The top 260also includes slots 262 to engage the legs 268 of the existing draftdiverter 112 illustrated in FIG. 26. When this top 260 is fit onto thebottom 258 the damper flapper valve housing 246′ forms a sheet metal boxthat supports and locates the existing draft diverter and is strongenough to support the secondary flue pipe of the installation leadingout of the dwelling.

It should be noted that while the damper flapper valve housing 246′illustrated in FIGS. 26 and 27 is a rectangular configuration, the outerperiphery may take on other configurations, for example, round. In sucha configuration, a mounting adaptor housing 248 such as that illustratedin FIGS. 21 and 22 may be utilized for mounting of the rotary damperactuator valve 114 thereon. Alternatively, the mounting bracket for therotary damper actuator valve 114 may be configured to mount to such acurved damper flapper valve housing 246′ configuration.

With a thorough understanding of various embodiments of the componentsof the standby energy loss prevention system 102 of the presentinvention, attention will now be turned to FIGS. 28-32, which illustratethe gas flow through the system at each stage of operation. The presenceof gas is illustrated in these figures as a darkened area in the pipingand/or components. For example, in FIG. 28, gas is present in gas supplypipe 208 at the inlet to the combination gas controller 130, such ase.g. a Robertshaw R110, R220 or SIT AC3 controller. However, since inthis figure the combination gas controller 130 has not initiated a callfor heat, there is no gas in the outlet gas feed pipe 132 leading to thedual safety relay valve 122.

As illustrated in FIG. 29, when the thermostat in combination gascontroller 130 calls for heat, the internal gas valve opens allowing gasto flow through the combination gas controller 130 and the outlet gasfeed pipe 132 to the inlet of the closed dual safety relay valve 122. Abypass flow of gas is piped from the inlet of the dual safety relayvalve 122 though the micro bore piping 120 to the rotary damper actuatorvalve 114. The size of the micro bore piping 120 may vary somewhat, andis preferable in the range of about 3 mm to 5 mm aluminium tube fortypical hot water heater installations.

The rotary damper actuator valve 114 is pressurised as shown in FIG. 30,which rotates the shaft 192. The rotary movement of shaft 192 rotatesthe crank shaft 190, thereby opening the damper flapper valve 118.Continued movement of the piston 224 (see FIGS. 10-12) in the rotarydamper actuator valve 114 will eventually drag the damper actuatorsafety valve 200 off its seat. As discussed above, the design is suchthat gas will not issue through the damper actuator safety valve 200until the damper flapper valve 118 is sufficiently open for goodcombustion.

As illustrated in FIG. 31, the opened damper actuator safety valveallows the gas to bleed from the rotary damper actuator valve 114,through micro bore piping 128 back down to the dual safety relay valve122. In embodiments that include a booster pilot, the flow from therotary damper actuator valve 114 is at a faster rate than issues fromthe booster pilot outlet, thus pressurising the dual safety relay valve122 diaphragm. The bleed gas starts to pressurize the relay diaphragmand is also bled to the booster pilot which ignites from the micro-pilotin such embodiments that includes a booster pilot (see FIG. 9), orincreases the gas flow to the pilot in embodiments that include thisfeature (see FIG. 8).

As illustrated in FIG. 32, once the dual safety relay valve 122 isfinally pressurized, both of its main gas valves are forced open againstthe gas pressure and return spring force. Gas then issues to the mainburner 148 via the burner feed pipe 134, where it is ignited by thepilot or booster pilot. In embodiments such as shown in FIGS. 8 and 9,gas continues to bleed from the dual safety relay valve 122 continues tobe burnt in the combustion chamber when the main burner 148 is on.

Once the combination gas controller 130 determines that the watertemperature has reached its set point temperature, it turns off all gasto the dual safety relay valve 122. Gas drains out of the damper of therotary damper actuator valve 114 where upon the safety valve returnspring closes the damper actuator safety valve 200 as the shaft 192begins to rotate under decreasing pressure on the piston 224, rotatingthe crankshaft 190 which begins to close the damper flapper valve 118.Gas continues to drain from the damper actuator safety valve bypass 202and from the diaphragm chambers of the dual safety relay valve 122,which allows the return springs 160, 214 to close off both of the maingas valves 158, 212 thus stopping all gas to the burner. The burner mainflame is extinguished as well as the booster pilot leaving only thepilot or micro-pilot on.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

1. A dual safety relay valve, comprising: a housing forming an inlet forreceiving gas; a first and a second main controlling valves positionedin series between the inlet and outlet but oriented anti-parallel to oneanother to control a flow of gas from the inlet to the outlet, the firstand the second main controlling valves each including a valve controlshaft drivably coupled to a diaphragm positioned in a diaphragm controlchamber;
 2. The dual safety relay valve of claim 1, wherein the housingfurther defines a booster pilot gas connection outlet in fluidcommunication with the diaphragm control chamber.
 3. The dual safetyrelay valve of claim 2 for use in a gas burning appliance including apilot supplied with gas by a pilot feed pipe, and wherein the boosterpilot gas connection is operatively coupled to the pilot feed pipe tosupply additional gas thereto to increase a size of a pilot flameproduced by the pilot to aid ignition of the burner.
 4. The dual safetyrelay valve of claim 2 for use in a gas burning appliance including amicro pilot supplied with gas by a pilot feed pipe, further comprising abooster pilot positioned in proximity to the micro pilot and the burnerand in fluid communication with the booster pilot gas connection.
 5. Thedual safety relay valve of claim 1, wherein the housing further definesa first connection port in fluid communication with the inlet and asecond connection port in fluid communication with at least one of thediaphragm control chambers.
 6. The dual safety relay valve of claim 5,wherein each of the diaphragm control chambers are in fluidcommunication with the second connection port such that an opening ofthe first and the second main controlling valves occurs at approximatelythe same time.
 7. The dual safety relay valve of claim 5, wherein thediaphragm control chamber of the first main controlling valve is influid communication with the second connection port and wherein thediaphragm control chamber of the second main controlling valve is influid connection with a gas flow chamber located downstream of a valveseat of the first main controlling valve such that the opening of thefirst and the second main controlling valves occurs in sequence.
 8. Arotary damper actuator valve, comprising: a housing defining an inletand an outlet; a diaphragm and a piston pivotably positioned within thehousing and operably coupled to a shaft, the piston coupled to a safetyvalve connection hook that engages a damper actuator safety valvepositioned between the inlet and the outlet such that the safety valveconnection hook must traverse a damper actuator safety valve dragdistance before the safety valve connection hook causes the damperactuator safety valve to open.
 9. The rotary damper actuator valve ofclaim 8, wherein a flow of gas into the inlet results in displacement ofthe diaphragm and piston causing rotation of the shaft, and whereinafter the diaphragm and piston have been displaced by the damperactuator safety valve drag distance the safety valve connection hookopens the damper actuator safety valve to allow the gas to flow from theoutlet.
 10. The rotary damper actuator valve of claim 8, furthercomprising a spring applying a bias force to close the damper actuatorsafety valve.
 11. The rotary damper actuator valve of claim 10, whereinthe spring is a coil spring coupled to the shaft to return the diaphragmand piston to a quiescent position.
 12. The rotary damper actuator valveof claim 11, further comprising a detent mechanism operably coupled tothe damper actuator safety valve to hold the damper actuator safetyvalve in an open position until the coil spring returns the diaphragmand piston near its quiescent position.
 13. The rotary damper actuatorvalve of claim 10, wherein the spring is a tension spring coupled to thedamper actuator safety valve.
 14. The rotary damper actuator valve ofclaim 13, wherein the damper actuator safety valve includes a bypasstherethrough.
 15. A damper flapper valve for use in a gas burningappliance having a burner and a flue pipe for exhausting combustiongases from the burner, the damper flapper valve being installed inproximity to the flue pipe such that closure of the damper flapper valvereduces thermal communication from the flue pipe to an environment,comprising: a flapper translatable between an open and a closedposition; and a rotatable crank shaft operably coupled to the flappersuch that rotation thereof translates the flapper between the open andthe closed positions.
 16. The damper flapper valve of claim 15, whereinthe gas burning appliance is a water heater configured for outdoorinstallation having a balanced flue terminal enclosing the flue pipe,further comprising: a valve seat bracket configured for fitment withinthe balanced flue terminal, the valve seat bracket having a top surfacedefining an opening therethrough configured and positioned above theflue pipe for fluid communication of flue gasses therethrough, the valveseat bracket having positioning legs; and wherein the damper flappervalve is positioned in proximity to the valve seat bracket such that atransition between the top surface and the positioning legs serves as afulcrum for the damper flapper valve.
 17. The damper flapper valve ofclaim 15, further comprising a damper flapper valve housing having avalve seat ring positioned therein, the valve seat ring forming an upperand a lower valve seat surface for contact with the damper flapper valvein a closed position.
 18. The damper flapper valve of claim 17, whereinthe flapper includes radius transition tabs offset from a center line ofthe flapper to provide off center weighting thereof.
 19. The damperflapper valve of claim 17, wherein the damper flapper valve housing iscylindrical with a diameter larger than a diameter of the flue pipe. 20.The damper flapper valve of claim 17, wherein the damper flapper valvehousing is rectangular having a base and a top and forming a centralpassage therethrough having a diameter larger than a diameter of theflue pipe, the damper flapper valve being positioned within the centralpassage.